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Installation Manual: Corrugated Steel Pipe Pipe Arches Structural Plate
Installation Manual: Corrugated Steel Pipe Pipe Arches Structural Plate
Manual for
➤ Corrugated Steel Pipe
➤ Pipe Arches
➤ Structural Plate
N AT I O N A L C O R R U G AT E D S T E E L P I P E A S S O C I AT I O N
INSTALLATION MANUAL — NCSPA
* * *
* * *
TABLE OF CONTENTS
FOREWORD .............................................................................................. 3
BASIC PRINCIPLES FOR PROPER
CONSTRUCTION AND INSTALLATION ............................................. 4
LOCATION ................................................................................................. 5
EXCAVATION............................................................................................. 5
Embankment Condition.................................................................. 5
Trench Condition............................................................................ 5
Trench Width and Shape ................................................................ 6
PREPARING FOUNDATIONS................................................................. 7
Handling Poor Foundations............................................................ 7
Uneven Foundations ....................................................................... 8
Soft Foundations............................................................................. 9
Pockets of Unstable Soil ................................................................ 9
Swampy Foundations ................................................................... 10
Improved Foundations.................................................................. 10
Settlement Under High Fill Loads ............................................... 10
Rock Foundations......................................................................... 11
Arch Foundations ......................................................................... 11
ASSEMBLY............................................................................................... 12
Unloading and Handling .............................................................. 12
Connecting Bands ........................................................................ 12
Installing Connecting Bands ........................................................ 12
Typical Connecting Bands ........................................................... 14
Gaskets ......................................................................................... 16
Mastic ........................................................................................... 17
Asphalt Coated Pipe ..................................................................... 17
Paved-Invert Pipe.......................................................................... 17
Full Lined Pipe ............................................................................. 18
Polymer Coated Pipe.................................................................... 18
Pipe Arch ...................................................................................... 18
Field Coated Structural Plate Structures ...................................... 18
Structural Plate Structures............................................................ 18
Tools Required ............................................................................. 19
Erection ........................................................................................ 19
Long Span Structures ................................................................... 21
08 InstallMan00
ASSEMBLY (continued)
Cut-Off Walls ............................................................................... 23
End Sections ................................................................................. 24
Other End Finishes ....................................................................... 24
Stream Diversion .......................................................................... 24
BACKFILLING ........................................................................................ 25
Backfill Material........................................................................... 25
Placing the Backfill ...................................................................... 25
Pipe Arches................................................................................... 30
Arches........................................................................................... 30
Large Diameter Structures ........................................................... 32
Proper Material Placement ........................................................... 32
Even Placement of Backfill.......................................................... 33
Shape Control ............................................................................... 33
Multiple Installations.................................................................... 34
Long Span Structures ................................................................... 35
Final Backfilling........................................................................... 35
COMPACTION EQUIPMENT ............................................................... 35
Hand Compaction......................................................................... 35
Mechanical Compactors ............................................................... 36
Roller Compactors........................................................................ 36
Vibrating Compactors .................................................................. 36
Hydraulic Compaction ................................................................. 36
Structure Protection...................................................................... 36
Construction Loads ...................................................................... 37
Hydraulic Protection .................................................................... 38
SUMMARY ............................................................................................... 40
SUBDRAINAGE ....................................................................................... 41
Underdrain Pipe............................................................................ 41
Flow Line ..................................................................................... 41
Preparing the Foundation ............................................................ 41
Assembly of Underdrain Pipe ...................................................... 41
Proper Placement of Underdrain Pipe.......................................... 42
APPENDIX................................................................................................ 44
Culvert Grades and Outfall Treatment ......................................... 44
Length of Culverts........................................................................ 44
Skew Number ............................................................................... 47
CSP Installation Manual 3
FOREWORD
This manual is intended for both the contractor and the engineer. It provides
practical information for the installation of corrugated steel pipe as storm
sewers or culverts. It also provides the necessary considerations for proper
design to achieve long term performance of the culvert or storm sewer.
Corrugated steel pipe with its high load carrying capacity, strong joints and
exceptional beam strength is installed more easily than other types of con-
duit. However, the correct installation procedures must be followed to insure
full investment value in the structure.
OSHA safety regulations and guidelines must be observed during all phases
of construction including foundation preparation, excavation, pipe handling,
assembly and backfilling.
This manual uses dual units of measure with Imperial units shown first fol-
lowed by metric units in parentheses. Complex drawings or tables may be
duplicated in metric.
4 National Corrugated Steel Pipe Association
The following summary will appear again near the end of the manual.
However review it now as a basic outline of the steps required for a proper
installation:
LOCATION
Before installing any drainage structure, it is best to first recheck the planned
alignment and grade (position and percent of slope) of the pipe in relation to
the topography of the site. Even when complete construction plans are sup-
plied, a careful examination of the site should be made.
EXCAVATION
Embankment Condition
The only excavation typically required for an embankment condition is to
remove the topsoil, muck and organic matter and prepare a stable foundation
at the proper elevation and grade.
Trench Condition
Most storm sewers are installed in trenches. Although pipes can be easily
installed in a trench, there are some general guidelines that should be followed.
All trench excavation should proceed only after OSHA and other safety
requirements are met. Trench excavation normally proceeds in the upgrade
direction. Most trenching equipment is more efficiently operated in this man-
ner, and pipe sections are also more easily joined when progressing in this
direction. If excavated spoil is to be used as backfill, it should be stockpiled
at a safe distance from the edge of the trench. As a general rule, when trench
walls are unsupported, the distance from the trench edge to the toe of the
stockpiled material should not be less than one-half the depth of the trench.
When trench walls are protected by some form of sheeting or shoring, a safe
minimum distance between the trench edge and stockpiled material must still
be maintained, but will vary with soil and bracing types.
To minimize accidents and losses resulting from trenching operations the fol-
lowing procedures should be followed:
➤ Begin excavation only when installation of pipe can immediately
follow.
➤ Protect trench walls to insure their stability throughout the con-
struction period.
➤ Follow procedures that will keep the trench free of seepage and sur-
face waters.
➤ Excavate the trench at the same rate as pipe installation with a min-
imum distance, as dictated by safety, separating the two operations.
➤ Backfill the trench as soon as practicable after pipe installation.
PREPARING FOUNDATIONS
Foundation requirements should be detailed on the plan sheets. However,
field conditions often vary requiring special attention and alterations that are
discovered only during excavation. Any alterations should first be approved
by the Engineer.
All storm sewers and culverts must be installed with the area under the
haunches well compacted and all voids filled.
For corrugated steel pipe, the most popular method of preparing the founda-
tion is by excavating to a flat surface and then carefully tamping the fill under
the haunches of the pipe. Proper backfill density can be achieved by com-
pacting the soil with a wooden pole, 2 x 4, or the smaller sizes of pneumatic
tampers to eliminate all voids under the structure. See Figure 1 for typical
methods of bedding corrugated steel structures and the 2 x 4 description.
This “flat foundation” technique works well except for larger pipe-arches
and horizontal ellipses. The vee-shaped bedding technique for these struc-
tures is shown in Figure 12.
All pipe must be placed on stable earth or fine granular foundation. Never
install them on sod, frozen earth or on a bed that contains large boulders or
rock. When poor foundations with low bearing strength are encountered,
investigate the possibility of a change in pipe location. Otherwise, it may be
necessary to stabilize the poor foundation by a method described in the next
section.
Care must be taken to prevent water leaking through the fill or along the
pipe. When granular materials have been added for bedding, the ends of the
fill should be sealed against infiltration. This can be done by bedding the
ends in well compacted clay or by adding some type of end treatment such
as an end section or a cut off wall.
Uneven Foundations
When the excavated grade line reveals both soft and hard spots, the founda-
tion must be changed to make it as uniform as possible. Sometimes hard
spots can be excavated below grade and replaced with softer material.
Alternatively, it may be more economical to excavate the entire foundation
slightly below grade line and replace it with suitable, uniform material. In
any event, any abrupt changes from hard to soft foundation must be avoided.
Figure 2.
Soft Foundations
When soft, unstable material is encountered at the foundation level, it must
be excavated below the flow line grade and backfilled to grade with sand,
gravel, crushed stone or other suitable material. The zone of select material
must be adequate to support the pipe and backfill. When unexpected materi-
als are encountered, consult the Engineer.
Swampy Foundations
Corrugated steel pipe must not be placed in direct contact with pipe bents or
concrete cradles that are installed to help provide a foundation. Such sup-
ports, if used, should be built with a flat top and covered with an earth cush-
ion. In this way the flexible structure can develop side support without con-
centrating the load at any point.
Improved Foundations
(soft, uneven, unstable or swampy)
Whenever a foundation is stabilized by using a coarse granular material, con-
sideration of the bedding and backfill material becomes even more impor-
tant. Fine materials can migrate into coarser materials and geotextile separa-
tors are often required to prevent this migration.
Be careful not to raise the center of the pipe above the inlet, as this will pock-
et water in the pipe.
Rock Foundations
Rock encountered in the foundation must be removed to provide more than
the minimum bedding thickness underneath the bottom of the structure.
Excavate wide enough to avoid any possibility of the pipe resting on rock and
provide access to adequately haunch the pipe as shown in Figure 4. The exca-
vated area is then backfilled with compacted, granular soil to cushion the pipe.
Figure 4. Method of handling rock foundations. t = 1/2 inch (13 millimeters) per
foot (.30 meter) of fill over pipe, with 24 inches (.60 meter) the maximum.
Arch Foundations
Arches differ from other structural plate structures in that they are generally
erected on concrete foundations. The key way or unbalanced channel in
which the arch rests must be accurately built to the proper line, grade and
spacing for easy assembly of the plates. The unbalanced channels must be
carefully located to insure that the holes correctly align with those in the
plates to permit bolting. They must be properly oriented (angled) to receive
the plate.
12 National Corrugated Steel Pipe Association
ASSEMBLY
Unloading and handling
Pipe must never be dumped directly from a truck bed while unloading.
Since corrugated steel pipes are relatively light weight, they can be handled
with light equipment. Use of slings is recommended to properly handle the
pipe.
Connecting Bands
The usual method of joining two or more lengths of pipe or pipe arch is by
steel connecting bands. The bands engage the ends of each pipe section. They
are placed to overlap each pipe section equally. The corrugations on the band
must fit into the corrugations of each pipe. Tightening of bolts draws the
band tightly around the adjacent ends of pipe lengths, providing an integral
and continuous structure.
One piece bands are used for most installations of smaller sizes of pipe.
“Two-piece” bands are used on larger diameter pipe and when installation
conditions are difficult. “Rods and Lugs” are used on levees, aerial sewers
and similar installations where bands that provide tighter and stronger joints
are essential.
Bands are put into position at the end of one section of pipe with the band
open to receive the next section. The next section is brought against or to
within 1 inch (25 millimeters) of the first section. After checking to see that
connecting parts of both band and pipe sections match, that the interior of
bands and exterior of pipe are free of dirt, stones, etc., bolts are inserted and
tightened.
On large diameter pipe and asphalt coated pipe, merely tightening bolts will
not assure a tight joint, due to the friction between the band and the pipe
ends. In such installation, tap the band with a mallet to take up the slack as
the band is tightened.
The wrench used to tighten coupling bands may be a deep socket or ratchet
wrench for greater speed.
Figure 4A. Typical connecting band is wrapped around the joint and drawn
together.
14 National Corrugated Steel Pipe Association
Standard Couplers
Flat Hat
Gasketed Couplers
Sleeve Gasket Mastic or Gasket
Semi-Corrugated (Hugger)
Figure 4B. Standard and Gasketed couplers for corrugated steel pipe.
CSP Installation Manual 15
Figure 4C. These typical band connectors are used with CSP coupling
systems.
16 National Corrugated Steel Pipe Association
Gaskets
Closed cell rubber, butyl rubber, neoprene, or closed cell rubber sponge gas-
kets are the basic types of materials to provide:
(1) “O” ring gaskets which are recessed in a corrugation and then con-
fined by the band after the joint is completed,
(2) flat gaskets placed on each end of the pipe forming a joint and con-
fined by the connecting band,
(3) a flat sheet gasket placed over the ends of both pipes,
(4) a gasket that is normally placed in the channel of the flanged band
connector.
For all field installed gaskets, a smooth round rod should be inserted under
the gasket and run around the circumference two or three times to equalize
the stretch in the gasket. On asphalt coated pipe it may be necessary to clean
the gasket groove to properly seat the gasket. The alignment and assembly of
the pipe sections is extremely important when gaskets are used. A lubricant
must be applied to the gasket for proper installation as recommended by the
manufacturer. When a tightness test is required for final acceptance, the con-
tractor should conduct his own test after a few joints are assembled as a
check of his assembly methods.
Figure 4D. Typical gaskets for use with connecting bands (where required).
CSP Installation Manual 17
Mastic
Mastic may be applied to the connecting band or pipe prior to placing and ten-
sioning the connecting band. A sufficient amount of mastic should be used to
fill the joint space between the corrugation and band with some squeeze out.
Paved-Invert Pipe
Pipe with an invert pavement must be stored and installed with the smooth,
thick pavement in the bottom. Otherwise installation of paved-invert pipe is
the same as for galvanized corrugated steel pipe.
If damage to the coating exposes the galvanizing, such areas must be patched
with asphalt or bitumen before the structure is backfilled.
When installations are to be made in hot weather, pipe lengths can be ordered
with an additional white coating on the pipe exterior to reduce the tempera-
ture of the pipe, if it is to be exposed to the bright summer sun for long peri-
ods. Prolonged storage of fully lined pipe should be avoided in any season.
Pipe Arch
Corrugated steel pipe arch structures are installed in the same manner as
round pipe. Recommendations regarding placement and connecting of vari-
ous types of pipe also apply to pipe-arch. However, because of its shape, par-
ticular care should be taken in installing pipe arch structures. (See page 30.)
Because of their multiple radius shape, pipe arches are not intended for
restrictive leakage or high cover applications.
The coating shall be applied to a clean surface, free of dirt, oil, grease, or
other foreign matter, when the atmospheric temperature is above 40°F (4°C).
and the humidity is low enough that the surface of the metal can be kept dry.
Preparation of the base and backfilling are the same as those described for
corrugated steel pipe.
Tools Required
Proper tools will speed the erection of structural plate. They include struc-
tural and socket wrenches, lining bars, drift pins and handling hooks.
If power wrenches are used, check bolt tightness very carefully as it is easy
for these wrenches to get out of adjustment. The proper use of a long handled
structural socket wrench or torque wrench will insure that bolts are properly
tightened.
Erection
Every structural plate structure is shipped complete with all necessary plates,
bolts and nuts for erection. Inside one of the containers of bolts (clearly
marked) are detailed erection instructions, showing the position of each plate
and order of assembly.
Assemble and connect each plate to adjacent plates with loose bolts near centers
of plates in longitudinal and circumferential seams. After assembly of all plates,
insert bolts working toward corners of plates. Keep bolts loose. Insert corner bolts
after all other bolts are in and tightened.
Tighten nuts progressively and uniformly, starting at one end of the structure,
after all plates have been assembled. Then repeat the operation to be sure
bolts are tight. From 100 to 300 foot-pounds (140 to 400 newton~meters) of
torque should be applied. Do not over torque.
A good plate fit is far more important than high bolt torque. Some structures
require alternate procedures—refer to the manufacturer's assembly instructions.
Lifting Assistance
Generally speaking, if the diameter or rise of the structural plate structure is
beyond the extended arms of the average construction worker, he should be
provided some type of lifting equipment or scaffolding. If powered lifting
equipment is not feasible or readily available, here are other ways of simpli-
fying assembly:
1. An “A” frame, utilizing man-powered block and tackle.
2. A lifting hoist built into the bed of a flat-bed truck.
3. Bed of a flat-bed truck, if size of structure permits the truck to be
driven inside.
4. A combination of scaffolding built inside the structure and ladders
outside. Or a flat-bed truck plus scaffolding.
End Treatment
In many cases, the ends of corrugated steel pipe that project, through the
embankment can be simply specified as square ends, that is, not beveled or
skewed. The square end is lowest in cost and readily adaptable to road widen-
ing projects. For larger structures, the slope can be warped around the ends
to avoid severe skews or bevels on the pipe end in many cases. When desired
for hydraulic considerations, flared end sections can be furnished for shop
fabricated pipe. Such end sections can be bolted directly to the pipe.
Cut Ends
By cutting the ends of corrugated steel structures, the need for additional end
finish can often be eliminated. The cut ends, supplied to specified embank-
ment slopes, are furnished by the fabricator. Corrugated steel structures can
be supplied with a step-bevel, bevel or a combination of skew and bevel.
It is recommended the embankment slope around the bevel or skew cut ends
of a structure be protected against erosion and piping by riprapping around
the structure end with stone, bags filled with dry sand-cement mixture, or by
the use of a slope reinforcing pavement. See Figure 9.
The maximum angle permissible for unreinforced skew cut ends is depend-
ent on the pipe's span (or for multiple runs, their combined span) as well as
the fill slope. Greater spans or steeper fill slopes limit the degree of skew that
can be used without reinforcement. When the permissible skew angle is
exceeded, the cut ends must be reinforced with masonry, concrete headwalls
or ring beams.
CSP Installation Manual 23
For larger span structures or multiple runs, this limit needs to be viewed in
regard to maintaining a reasonable balance of soil pressures from side to side,
perpendicular to the structure(s) centerline. For single or multiple structures,
the design engineer must provide the proper reinforcement and end protec-
tion in the plans and specifications.
Long bevels for slopes greater than 2:1 with or without skews, should be
avoided. The long cut ends require extra care in design, erection and backfill.
It is preferable to use a steep bevel without a skew and then warp the fill
slope to fit the structure. Cut ends of corrugated steel structures, where the
bevel exceeds 2:1 and/or the skew is greater than 15 degrees, should have the
ends reinforced with masonry or concrete headwalls and anchored in accor-
dance with specifications. More in depth information on design limits is pro-
vided in the AISI Handbook of Steel Drainage and Highway Construction
Products.
Cut-off Walls
Cut-off walls protect the structure from hydraulic uplift pressures below its
invert and from dynamic flow forces. While cut-off walls are often unneces-
sary in small diameter applications, equalizer pipes, etc., larger structures,
24 National Corrugated Steel Pipe Association
pipes with a large bottom radius such as pipe arches or other pipes in appli-
cations where currents are swift or water levels rise or fall quickly are more
susceptible to hydraulic damage. These latter conditions should be investi-
gated by the design engineer.
End Sections
End Sections provide a practical and economical method of finishing cul-
verts. Sections are attached to the pipe or pipe arch ends by simple connec-
tors—similar to coupling bands used in joining pipe sections—and can be
completely salvaged if lengthening or relocating the culvert is necessary.
Stream Diversion
If the stream is temporarily diverted during construction, the diversion ditch
or temporary drainage pipe must be adequate to carry the storm flow. Short
construction times of course are helpful in limiting this exposure. The pipe
installation must be protected from storm flows by a temporary dike, coffer-
dam, etc.
If the structure must carry the flow during the construction stage, the
upstream end must be protected with the proper end treatment, etc. to ensure
that the flow is not diverted around or beside the pipe thereby scouring out
backfill as it is placed or floating the pipe. In phased construction, it is desir-
able to construct and backfill the upstream end first. (See Hydraulic
Protection, page 38.)
CSP Installation Manual 25
BACKFILLING
The load carrying capacity of any type of pipe is largely dependent upon
proper backfilling. Corrugated steel pipes build up side support as they
deflect under load.
Therefore to obtain maximum strength and prevent washing out and settle-
ment, it is necessary that the backfill be made of good material, properly
placed, carefully compacted and protected.
Figure 10. Pipe side support is developed by slight pipe deflection under load.
Backfill Material
Selected, drainable materials achieve the best results. However, many local
fill materials may do the job if carefully placed and compacted. Consult the
design engineer or a soils engineer for proper backfill selection. Well graded
granular material containing a small amount of silt or clay is ideal because is
makes a dense, stable fill. Fill material must be free from rocks and hard
earth clods larger than 3 inches (75 millimeters) in size. It must not contain
any frozen material, sod, cinders or earth containing organic matter.
For trench installations, backfill must follow as closely behind the excavation
and assembly stages as possible. Embankment installations typically are
backfilled after the entire structure, or a major portion of it, is assembled.
Unless the embankment and backfill materials are placed simultaneously,
one must be benched so the other can be compacted against it.
The backfill should be carefully compacted under the haunches (lower part
of structure exterior, below widest part); special care should be taken in
doing this for pipe-arches.
Continue placing the backfill equally on both sides of the pipe in 6 to 8 inch-
es (.15 to .20 meters) of compacted layers thoroughly compacting each layer
to a 90% Standard Proctor density (AASHTO T99). Such compacted layers
must extend to the limits shown on the plans on each side of the structure, or
to the side of a trench, or to the natural ground line.
Backfill must be placed and fully compacted to the minimum cover level
over the structure before the pipe is subjected to highway or light construc-
tion loads. When construction equipment that exceeds legal highway
loads will cross the pipe, an extra thickness of compacted fill, beyond
that required for minimum or planned cover, is required. See
Construction Loads, page 37.
CSP Installation Manual 27
Side Fill
see Note (c)
Bedding Blanket
see Note (b)
Existing
Ground
Rough Excavation
for Bedding Blanket
NEGATIVE POSITIVE
PROJECTION PROJECTION
CONDITION CONDITION
NOTES
(a) For structural plate pipe, the length of bedding arc need not
exceed width of bottom plate.
(b) Bedding blanket of loose granular fill roughly shaped to fit bottom
of pipe. Minimum thickness before placing pipe shall be as fol-
lows:
1 inch (25mm) for 1/2 inch (13mm) deep corrugation
2 inches (50mm) for 1 inch (25mm) deep corrugation
3 inches (75mm) for 2 inches (50mm) deep corrugation
Side Fill
see Note (c)
see Note (a)
Side Fill
see Note (c)
see Note (a)
3D
or as planned
Compacted
structure backfill
see Note (c)
Densely compacted
granular fill under
haunches.
Figure 12. Recommended backfilling practice for larger pipe arch, using a vee-
shaped bed.
30 National Corrugated Steel Pipe Association
Pipe Arches
Special attention must be given to compaction of the backfill under the
haunches of the pipe arch. A softer or yielding foundation under the bottom,
as compared to the corners, is essential. See Figure 12. A vee-shaped bed for
larger pipe arches is recommended.
Arches
Care must be taken in backfilling arches, especially half-circle arches,
because they have a tendency to shift sideways or to peak under backfilling
loads. The ideal way is to cover an arch in layers-each layer conforming to
the shape of the arch. If one side is backfilled more than the other, the arch
will move away from the larger load. If both sides are backfilled equally and
tamped thoroughly, the top of the arch may peak unless enough fill has been
placed over it to resist the upward thrust. These precautions apply also to
other corrugated steel structures, but to a lesser degree.
When backfilling arches before headwalls are placed, the first material
should be placed midway between the ends of the arch, forming as narrow a
ramp as possible until the top of the arch is reached. The ramp should be built
evenly from both sides and the backfill material should be thoroughly com-
pacted as it is placed. After the two ramps have been built to the depth spec-
ified to the top of the arch, the remainder of the backfill should be placed and
compacted by extending the ramp both ways from the center to the ends, and
as evenly as practicable on both sides of the arch.
If the headwalls are built before the arch is backfilled, the backfill material
should first be placed adjacent to each headwall, placing and compacting
material uniformly on both sides of the structure until the top of the arch is
reached. Then backfill should proceed toward the center by extending the
ramp; with care being taken to place and compact the material evenly on both
sides of the arch. Top loading will help control peaking.
CSP Installation Manual 31
Spread backfill material with equipment running parallel to, not at right
angles to the structure.
Peaking or deflection action can be detected when the points of the bobs
move vertically. Corrective action is usually to keep heavy equipment further
away from the structure. Placing and compacting backfill in thinner lifts
and/or bringing the backfill to the proper moisture content will reduce the
necessary compactive effort and help to control peaking.
Rolling action can be detected when the plumb-bobs move laterally. It is cor-
rected by filling or compacting on the side towards which the plumb-bob has
moved. For example, a roll to the right will be corrected by higher fill on the
right.
Recommended minimum spacings for pipe, pipe-arch and arches are shown
in Figure 16. The spacings are for the use of all, standard backfill materials
and allow room for compacting the backfill.
The minimum spacing shown also provides adequate room between the pipe
and the trench wall for adequate material placement and compaction.
Whether the structure is large or small, keep in mind that the requirements of
economical equipment should also be considered in determining spacing
between the structures. For example, with structural plate structures it may
be desirable to utilize mobile equipment for compaction between the struc-
tures. The space between pipes should allow efficient operation and selection
of compaction equipment.
Final Backfilling
Once the envelope of backfill material is placed around and over the pipe and
properly compacted, the remainder of the fill, the final backfill, should be
placed and compacted to prevent settlement at the surface. The backfill mate-
rial and compaction level specified has been selected to prevent surface sub-
sidence, protect the pavement, etc.
When thick sheeting, such as wood, has been used to support the trench walls
be sure to fill and compact the voids left when it is withdrawn or, cut it off
above the crown of the pipe.
COMPACTION EQUIPMENT
Hand Compaction
For compacting the small areas under the haunches of a structure, a pole or
2 x 4 (see note under Figure 1) is generally needed. Hand tampers for hori-
zontal layers should weigh not less than 20 pounds (9 kilograms) and have a
tamping face not larger than 6 by 6 inches (150 x 150 millimeters).
Mechanical Compactors
Most types of power tampers are satisfactory in all except the most confined
areas. However, they must be used carefully and completely over the entire
area of each layer to obtain the desired compaction. Avoid striking the struc-
ture with power tamping tools.
Roller Compactors
Where space permits, sheepsfoot (recommended for clays and silts only),
rubber tired and other types of rollers—with the exception of smooth
rollers—can be used to compact backfill. But the fill adjacent to the structure
should be tamped with hand or hand-held power equipment.
Vibrating Compactors
Vibrating compactors can be used effectively on all types of backfill except
heavy clays or other plastic soils. Small walk behind equipment is especial-
ly suited to trench installations.
Hydraulic Compaction
The use of water flooding and/or jetting for compacting backfill around the
pipe is limited to compacting clean, granular soils. To be effective, the foun-
dation below the pipe must be sufficiently permeable to carry the water down
and away quickly. Backfill around and immediately above the pipe must be
placed and compacted in individual lifts of 6 to 8 inches (150 to 200 mil-
limeters) of compacted thickness.
Structure Protection
Often, construction loads exceed the finished design loads for the structure.
Additionally, during the various phases of assembly, backfill and construc-
tion the structure typically is more vulnerable to loadings and hydraulic
forces because its backfill, end treatment, etc. are not complete. The corru-
gated steel structure must be properly protected.
CSP Installation Manual 37
Construction Loads
Frequently, it is necessary for heavy construction equipment to travel over
installed corrugated steel structures during completion of grading, paving or
other site work. Heavy construction equipment can impose concentrated
loads far in excess of those the structure is designed to carry.
Adequate protection of the corrugated steel structure may require more than
finished design fill. The amount of additional fill needed depends on the
equipment axle loads as well as the frequency of use.
Figures 17 and 18 provide the minimum cover for typical structure sizes, axle
loads and construction use. While providing extra cover is a simple way to
protect the structure, it must be maintained so that rutting, surface grading,
etc. does not reduce its effect. A minimum crossing width of 24 feet (7.3
meters) is recommended for typical equipment.
Figure 19. Compacted side fill should be completed on both sides of structure
before fill is "carried over" for construction traffic.
Temporary dead loads resulting from storage piles, crane placements, etc.
must be evaluated as to structure capacity, loading balance, backfill support,
adequate foundation strength, and other factors that may be applicable to the
conditions.
Hydraulic Protection
During installation, prior to the completion of backfilling, permanent end
treatment, slope protection, flow controls, etc., the structure is vulnerable to
storm and flow conditions less than the final design levels. Hydraulic flow
forces on unprotected ends, unbalanced backfill loads, loss of backfill and
support due to erosion and uplift forces are examples of factors to be con-
sidered. While guidance is offered in some of the above sections, temporary
protection may need to be constructed.
Construction
Equipment Traffic
Construction
Cover Finished
Grade
Adequate, uniform compaction is the secret to building soil and steel structures.
40 National Corrugated Steel Pipe Association
SUMMARY
Proper installation of any drainage structure will result in longer and more
efficient service. This installation manual is intended to call attention to both
good practice and to warn against possible pitfalls. The principles apply to
most conditions. It is not a specification but an aid to your own experience.
SUBDRAINAGE
Underdrain Pipe
Underdrains, to remove ground water, must be properly installed to give
long, satisfactory service. With perforated steel underdrain pipe, correct
installation is fast and easy.
Flow Line
The flow line should be placed below water-bearing strata for most effective
drainage. However, if the strata is too deep to permit draining to a natural
outlet, the pipe can be placed within the water-bearing material if this would
permit natural drainage or a sump pump may be used. This does not provide
complete drainage but will lower the natural water table to a desirable level.
Outlets should be free and not subject to flooding or restriction by freezing
or debris and protected against damage by maintenance equipment.
Where possible, it is desirable to use a 0.2 percent minimum slope for all
subdrainage lines.
Locate perforations at
lower quarter points
for small diameter drains) may be in two pieces with matching corrugations
to fit this helically corrugated steel pipe or sleeve bands.
Many bank-run sands and concrete sand will make a satisfactory backfill for
perforated steel underdrains. Also, material having not more than 10% of its
weight in particles larger than 3/8-inch (9.5 millimeter) will also make a sat-
isfactory backfill.
This backfill material should be placed for a width of at least 6 inches (150
millimeters) on each side of the pipe and for the depth over the pipe neces-
sary to intercept all possible water-bearing strata. Above this area the trench
could be capped with other normal types of backfill material.
APPENDIX
Culvert Grades and Outfall Treatment
Length of Culverts
Length of a culvert depends upon roadway width from shoulder to shoulder
height of fill above flow line, side slope of the embankment, as well as align-
ment and grade.
Where culverts are to be installed at right angles to the road, their length can
be computed by the method presented in Figures 24 and 25. Note that when
culverts are on steep grades, their centers are offset with respect to roadway
centerline.
Lengths of corrugated steel pipe and structural plate pipe are normally sup-
plied in even increments of 2 ft. (.6 meter).
In order to obtain the correct skew cut on a pipe, use Figure 27 to determine
the proper skew number to give the manufacturer.
CSP Installation Manual 45
Use example in Figure 25, but the pipe is skewed 20° to the roadway (i.e.,
cross 20° off the perpendicular). The pipe is 4 ft. (1220 mm) in dia.
Skew Number
In order to obtain the correct skew cut on a pipe, use Figure 27 to determine
the proper skew number to give the manufacturer.
Figure 27.
48 National Corrugated Steel Pipe Association
NOTES
N ATIONAL C ORRUGATED S TEEL P IPE A SSOCIATION
1255 Twenty-Third Street, NW, Suite 200
Washington, DC 20037-1174
Phone: 202/452-1700 • Fax: 202/833-3636
E-mail: csp@ncspa.org • Web: www.ncspa.org